Noble metal acidic zeolites for isomerization

ABSTRACT

Disclosed is a method for preparing noble-metal containing zeolite materials suitable for isomerization reactions. The catalysts are prepared by contacting an zeolite selected from the acidic faujasite, LZ-210 type zeolites and mordenite with an effective amount of a noble metal compound selected from Pt(acetylacetonate) 2  or Pd(acetylacetonate) 2  then calcining at a temperature from about 250° C. to 600° for an effective amount of time.

FIELD OF THE INVENTION

The present invention relates to hydrogen from crystallinealumino-silicate zeolites for isomerization of paraffinic hydrocarbons.

BACKGROUND OF THE INVENTION

Catalytic isomerization is an important refinery process for convertingnormal paraffins to their higher octane isomer counterparts. Catalystsemployed to catalyze isomerization reactions include Friedal-Craftscatalysts, such as aluminum chloride; noble-metal catalysts, such asplatinum on halogenated alumina; and more recently, crystallinealuminosilicate zeolites. Both natural and synthetic crystallinealuminosilicates have been employed. These include zeolite X, Y, as wellas synthetic mordenite, especially hydrogen form mordenite.

While various degrees of commercial success have been achieved usingsuch catalyst systems, there is still a need in the art for catalystshaving improved isomerization properties.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a processfor producing a noble-metal containing acidic zeolite selected from thegroup consisting of acidic faujasites, LZ-210 type zeolites, andmordenite. The process comprises:

(a) treating the above mentioned acidic zeolite with a noble-metalcomposition selected from Pt(acetylacetonate)2 and Pd(acetylacetonate)2for an effective amount of time to incorporate the noble metal into thenear surface regions of the zeolite but not to disperse the noble metalthroughout the entire zeolite; and

(b) calcining the so treated zeolite at a temperature from about 250° C.to about 600° C. for an effective amount of time.

In preferred embodiment of the present invention the zeolite is anacidic faujasite or mordenite, and the noble metal is platinum.

BRIEF DESCRIPTION OF THE FIGURE

The sole figure thereof is a graphical representation depicting activityand selectivity advantages for hexane isomerization of the catalysts ofthis invention over conventionally produced noble-metal zeolitecatalysts.

DETAILED DESCRIPTION OF THE INVENTION

Zeolite compositions suitable for use herein are the acidic, or hydrogenform, 12-ring zeolites; such as acidic faujasite, LZ-210 type zeolite,and mordenite. Preferred are acidic faujasite and mordenite, and mostpreferred is acidic faujasite.

Mordenites expressed in terms of mole ratios of oxide, may berepresented as follows:

    (1.0±0.2)M.sub.2/n O:Al.sub.2 O.sub.3 :(10±0.5)SiO.sub.2

wherein M is an alkali or alkaline-earth metal, preferably sodium orpotassium; and n is the valence of M.

Because the alkali and alkaline-earth metal form of zeolite is notparticularly effective for the isomerization hydrocarbons, some or allof said metal is replaced with hydrogen ions, thereby resulting in amore advantageous hydrogen form for isomerization. This substitution ofhydrogen for alkali and alkaline-earth metal can be accomplished by anyconventional means. Non-limiting examples of such means include thedirect replacement of the metal ions with hydrogen ions by ion exchangemetals using an acidified aqueous solution. Another method involves thesubstitution of metal ions with ammonium ions followed by decompositionof the ammonium form using a high temperature oxidative treatment.Combinations of the acid and ammonium treatment for mordenite aredisclosed in U.S. Pat. No. 3,475,345 and U.S. Pat. N. 3,442,794, both ofwhich are incorporated herein by reference. In U.S. Pat. No. 3,475,345,a sodium form synthetic mordenite is converted to a hydrogen form in athree-step pretreatment procedure. That is, powered mordenite is firstsubjected to a hot acid treatment, followed by a cold acid treatment,followed by treatment with an ammonium compound.

It is preferred to use a mordenite having a relatively high silica toalumina ratio. Typically, a silica to alumina ratio of about 10:1 isobserved for a sodium form synthetic mordenite and is substantiallyunchanged if an ammonium treatment is used to convert the mordenite tothe hydrogen form. If the mordenite powder is subjected to an acidtreatment as taught in U.S. Pat. No. 3,597,155, an increase in thesilica to alumina ratio is effected. The acid treatment is believed tocause a reduction of the framework tetrahedra aluminum atoms, thusincreasing the proportion of silica atoms present in the zeoliticstructure. as taught in U.S. Pat. No. 3,507,931, a silica to aluminaratio above about 20:1 significantly improves the isomerization of lighthydrocarbons. U.S. Pat. No. 4,018,711 also teaches that isomerizationperformance is improved if a pretreated mordenite powder having a silicato alumina ratio of at least 19:1 is incorporated in a catalystcomposition. Further, the relatively high surface area, high silica toalumina mordenites taught in U.S. Pat. 4,735,929 are also suitable foruse herein.

Acidic faujasites are generally produced by substituting hydrogen ionsfor alkaline ions in an alkaline Y faujasite. The chemical formulaalkaline Y faujasite, expressed in terms of mole ratio of oxides may bewritten as:

    (0.7-1.1)M.sub.2/n O:Al.sub.2 O.sub.3 :xSiO.sub.2 :yH.sub.2 O

wherein M is an alkali or alkaline-earth metal, n is the valence of M, xis a value greater than 3 and up to about 6, and y may be a value up toabout 9. Zeolite Y has a characteristic X-ray powder diffraction patternwhich may be employed with the formula for identification. Zeolite Y isdescribed in more detail in U.S. Pat. No. 3,130,007, which is alsoincorporated herein by reference. The hydrogen, or acid form of thefaujasite is obtained by means similar to that for mordenite, discussedabove, except acidic faujasite is usually not obtained by directreplacement of the metal ions with hydrogen ions using an acidifiedaqueous solution.

The chemical formula for LZ-210 zeolite, expressed in terms of moleratio of oxides, may be written as:

    (0.7-1.1)M.sub.2/n O:Al.sub.2 O.sub.3 :(6-20)SiO.sub.2 :yH.sub.2 O

wherein M is an alkali metal or alkaline-earth metal, n is the valenceof M, and y may have a value up to about 8 depending on the identity ofM and the degree of hydration of the crystalline zeolite. ZeoliteLZ-210, its X-ray diffraction pattern, its properties, and method ofpreparation are described in U.S. Pat. No. 4,503,023, which isincorporated herein by reference. By LZ-210 type zeolite, I mean LZ-210zeolite itself or a zeolite which is isostructural to LZ-210.

Another preferred catalyst of this invention, ultrastable zeolite Y,(USY), is described in detail in U.S. Pat. No. 3,449,070 which is alsoincorporated herein by reference. USY-zeolite, which is ultrastable atelevated temperatures, can be written as:

    xM.sub.2/n O·Al.sub.2 O.sub.3 :(3.5-7)SiO.sub.2 :yH.sub.2 O

where M represents H+or any other cation except the alkalis; n is thevalence of M and can be 0 to 1; y can vary from 0 to 9; and x is from 0to 1.

The compositions of the present invention are prepared by treating thezeolite with an effective amount of a noble-metal containing compoundselected from Pt(acetylacetonate)₂ or Pd(acetylacetonate)₂, alsosometimes referred to herein as Pt(acac)₂ and Pd(acac)₂. An effectiveamount of noble metal compound is that amount which will result in acatalyst containing from about 0.5 to 10 wt. %, preferably from about0.5 to 5 wt. %, and more preferably from about 0.75 to 1.5 wt. % noblemetal, based on the total weight of the catalyst. The zeolite can betreated by merely mixing together the Pt-and/or Pd(acac)₂ and zeolite;or by treating the zeolite with the Pt-and/or Pd(acac)₂ in an organicsolvent, such as toluene, for an effective amount of time. Effectiveamount of time means for a time which will allow the Pt and/or Pd to beintroduced into the zeolite at or near the surface, but not so long asto allow the Pt and/or Pd to be impregnated throughout the entirezeolite structure. That is, the noble metal will be impregnated no morethan 90%, preferably no more than 80%, into the interior of the zeolite.After the zeolite is treated with the Pt-and/or Pd(acac)₂, it iscalcined at a temperature from about 250° C. to about 600° C. If thezeolite and the Pt or Pd(acac)₂ are dry-mixed, the dry-mix must becalcined for the same effective amount of time as indicated above. Forexample, at a temperature from about 300° C. to about 400° C. aneffective amount of time will be from about 5 minutes to about 4 hours.

It has unexpectedly been found that only when the noble metal containingzeolite materials of the present invention are prepared by the method ofthis invention, do they show unexpected activity for isomerization. Thatis, the catalyst maintains an unexpectedly high degree of activity foran extended period of time. If platinum, and/or palladium, isincorporated into the zeolite in accordance with prior art methods, suchas by ion-exchange, or by treatment with an aqueous solution of a saltof a platinum or palladium complex, such as hexachloroplatinic acid,dinitrodiaminoplatinum or platinum tetramine chloride, the resulting Ptand/or Pd-containing zeolite do not show the unexpected advantages forisomerization.

Hydrocarbons which may be isomerized by the process of this inventioninclude paraffinic and olefinic hydrocarbons typically having 4-20,preferably 4-12, more preferably about 4-6 atoms; aromatic hydrocarbonssuch as xylenes. The preferred chargestock is comprised of paraffinichydrocarbons typified by butanes, pentanes, hexanes, heptanes, etc.

The instant catalysts may find use in isomerization processes whereinthe position of the double bond is changed as typified by the conversionof butene-1 to butene-2. They may also be used in disproportionationprocesses such as the conversion of toluene to benzene and xylene or intransalkylation processes such as the reaction of benzene and zylene toproduce toluene.

Prior to use of the calcined catalyst composition, it is preferred toprecondition the composition by heating, in a flowing stream ofhydrogen, to 450oF-1000oF, preferably 500-675oF say 550oF for 2-10hours, preferably 2-4 hours, say 3 hours. Pretreating, likeisomerization, is preferably carried out under substantially anhydrousconditions.

Isomerization in accordance with the process of this invention may becarried out by passing the charge isomerization hydrocarbon into contactwith the preconditioned catalyst in the presence of hydrogen, at thefollowing conditions:

    ______________________________________                                        Conditions     Broad     Preferred Typical                                    ______________________________________                                        Temperature, °F.                                                                      400-500   400-450   435                                        Pressure, psig   0-1000   0-300    250                                        LHSV           0.1-20    0.1-2      1                                         Hydrogen Rate, SCFB                                                                          1000-5000 1500-2500 2300                                       ______________________________________                                    

The catalyst may be in the form of granules, e.g., 10 to 25 mesh TylerStandard screen Scale, and preferably is in the form of pellets orextrusions having a diameter of about 1/16 inch. The reaction issuitably carried out over a fixed bed of catalyst with the hydrogen andfeedstock passing downwardly through the catalyst bed. Unreactedhydrogen may be separated from the effluent stream from the catalyst bedand recycled to the process.

Operating temperature and catalyst activity are correlated with spacevelocity to give reasonably rapid processing of the feedstock atcatalyst deactivation rates which insure maximum on-stream time of thecatalyst between periods of regeneration.

As the catalyst ages, its activity for the desired reaction tends toslowly diminish. The catalyst may be maintained at or periodicallybrought back to approximately its initial level of activity byincreasing the operating temperature as the catalyst ages.

The following examples serve to more fully describe the presentinvention. It is understood that these examples are not intended tolimit the true scope of this invention, but rather are presented forillustrated purposes.

n-Hexane Test

To illustrate the hydroisomerization activity and selectivity of thecatalysts of this invention n-hexane was isomerized at a standard set ofconditions of temperature, hydrogen pressure and rate, and at a fixedspace velocity (weight liquid feed per hour per weight of catalyst). Theconversion is measured by the disappearance of the n-hexane feed, andthe selectivity by the increase in research octane number, clear (RONC).This value is calculated from the known octane number of the hexaneisomers. The feed, n-hexane, has a RONC of 25, while the isomers are allmuch higher, 73 to 104.

COMPARATIVE EXAMPLE 1

A platinum on hydrogen-mordenite was prepared by ion-exchanging ahydrogen-mordenite with Pt(NH₃).sub.²⁺, washing and air calcining. Themordenite has a molar ratio of SiO₂ to Al₂ O₃ of 16.3, less than 0.01%sodium, and after exchange contained 0.5% Pt.

EXAMPLE 1

A platinum on LZY-82 was prepared by blending together 100 gms ofcalcined LZY-82 (an acidic faujasite available from Union Carbide Co.)with 1.32 gms of Pt(acetylacetonate)₂ then rapidly calcining themixture. This resulted in a Pt on acidic faujasite containing 0.66 wt.%Pt.

The above two catalysts were tested in a 1/2 inch diameter stainlesssteel reactor mounted in an electrically heated sand bath. Thetemperature was varied between 200° C. and 250° C. At thesetemperatures, the hydrocracking of the hexane to lower carbon numberproducts is small (approximately 2 wt.% of the total feed). Further, thecatalysts show very little decline in activity over hours of operationat these conditions, indicating no significant coking has occurred.

The precise conditions of the above catalyst testing was a totalpressure of 250 psig, 3000 SCF of hydrogen per barrel of hexane feed,and one space velocity. At these conditions, in the temperature range of200° C. to 250° C., the thermodynamic n-hexane conversion ranges from 90to 80%, so that catalysts more active than the Pt on mordenite byconventional means are expected to be found. The conversion and octaneresults for both the comparative catalyst and the catalyst of thisinvention can be found in the figure hereto.

What is claimed is:
 1. A method for producing a noble metal containingzeolite catalyst for isomerization of paraffinic hydrocarbons whichmethod comprises: (a) contacting a zeolite material selected from thegroup consisting of acidic faujasites, LZ-210 faujasites, and mordenitewith a noble-metal compound selected from Pt(acetylacetonate)₂ andPd(acetylacetonate)₂ for an effective amount of time to incorporate Ptand/or Pd into the pore surface regions of the zeolite, but not todisperse the Pt and/or Pd throughout the entire zeolite; and (b)calcining the so treated zeolite at a temperature from about 250° C. toabout 600° C. for an effective amount of time.
 2. The method of claim 1wherein the zeolite is an acidic faujasite.
 3. The method of claim 2wherein the acidic zeolite is ultrastable Y faujasite.
 4. The method ofclaim 1 wherein the zeolite and the noble-metal compound are contactedas a dry-mix.
 5. The method of claim 4 wherein the dry-mix is calcinedat a temperature from about 300° C. to about 400° C.
 6. The catalystprepared in accordance with claim
 1. 7. The catalyst prepared inaccordance with claim 3.